Method of manufacturing embedded water soluble film carrier

ABSTRACT

This invention relates to a water-soluble film (WSF) system with embedded/entrapped water-soluble films (WSF). More particularly, the invention relates to a WSF system with actives embedded/entrapped therein such as to provide precise and desired release of actives there from and its method of manufacturing for diverse applications, in which a variety of substances such as detergents, enzymes, softeners, perfumes, pesticides, fungicides, active ingredients, dyes, pigments, hazardous chemicals, active agents for cleaning laundry, dishes, floorings, walls, furniture, fluffs, pulp, etc., and the like can be so embedded/entrapped for such purpose. The invention further discloses novel online and offline process for the manufacture of such multi-layered WSF with or without liners and of desired shapes to selectively entrap interacting/non-interacting materials and their combinations. The process also provides options for the use of a wide range of raw materials, liners such as paper, film, foil, fabric, etc.

FIELD OF INVENTION

[0001] This invention relates to a water soluble film (WSF) system withembedded/entrapped water-soluble films (WSF) and a process ofmanufacturing the same. More particularly, the invention relates to aWSF system with actives embedded/entrapped therein such as to provideprecise and desired release of actives therefrom and its method ofmanufacturing for diverse applications, in which a variety of substancessuch as detergents, enzymes, softeners, perfumes, pesticides,fungicides, active ingredients, dyes, pigments, hazardous chemicals,active agents for cleaning laundry, dishes, floorings, walls, furniture,etc., and the like can be so embedded/entrapped for such purpose.

BACKGROUND ART

[0002] In various processes/operations and in day-to-day life, a numberof substances including hazardous or non-hazardous chemicals arerequired to be delivered in the precisely measured doses.

[0003] Attempts by the packaging industry has been to develop approachesto evolve accurate delivery systems for active materials especiallythose that are expensive or are environmentally sensitive or havepossibilities of reacting with other ingredients in formulations. Therehave been several attempts in the past to either encase or laminate orpackage different materials in water-soluble films (WSF).

[0004] The objective of delivering precise quantities of products likedetergents have been being addressed by the industry for example bypackaging detergents in “soluble” and “non-soluble” sachets in dosagesranging from 20 gms/sachet to 50 gms/sachet. In case of non-solublesachets the detergents tend to adhere to statically charged packagingmaterial surface thereby inhibiting their total transfer to the point ofapplication. Similar problems of particles adhering to staticallycharged surface are faced when small and precise quantities ofpesticides actives are to be packed in non soluble sachets. In the caseof soluble sachets problem arising out of chemical reaction of theingredients to the film cause serious problems in its smoothapplications. Similarly in the case of pesticide packaging the activeingredients in the package varies from about 2% to about 30% based onthe formulation.

[0005] U.S. Pat. No. 4,416,791 discloses a packaging film comprising abase film of at least partially water-soluble plastics material carryingon one surface only a protective layer, in particulate form, of an inertplastics material having a contact angle to water of at least 80.degree,the said layer being effective to protect the base film surface fromattack by aqueous media. Such a packaging film has the advantages that,on its unprotected side, it can be dissolved away, or partly dissolvedand partly dispersed, by water, whereas on the side carrying theprotective layer it is protected from attack by aqueous systems andother aggressive media. It is essential that the inert protective layerbe in the form of substantially un-coalesced discrete particles attachedfirmly to the base film but only loosely or not at all to each other, sothat if the base film is dissolved away the protective layer has littleor no integrity and is rapidly dispersed. Further it provides a packagecomprised of the packaging film defined above, having the protectivelayer on its internal surface(s), so that the layer protects the packagefrom attack by any water present inside the package. It is claimed thatsuch a product can be used to package liquid or solid detergent usefulfor dosing into domestic or commercial washing machines.

[0006] In one of the methods described in the patent acold-water-soluble polyvinyl alcohol/polyvinyl acetate film having athickness of 0.0038 cm was heated to a temperature just above its glasstransition temperature to render it slightly tacky.Polytetrafluoroethylene powder is sprinkled onto the upper surface ofthe heated film. The film is then passed between rollers heated and thenallowed to cool.

[0007] The limitation of U.S. Pat. No. 4,416,791 is that it requires apre formed WSF substrate and the extent of coating of thePolytetrafluoroethylene powder would be restricted to the surface of theWSF. By this process it would not be possible to control the depth towhich the Polytetrafluoroethylene powder can be embedded.

[0008] The end use of this invention would be limited to the waterrepelancy and the release properties of Polytetrafluoroethylene powderon the surface of the pre formed WSF.

[0009] U.S. Pat. No. 4,176,079 discloses an invention for dispersing anenzyme into water soluble resin and forming the resin by casting orextruding into a sheet. The sheet is then dried, if necessary, and, ifrequired, cut into “ribbons” for incorporation into the detergentproduct. The ribbons of enzyme-dispersed resin may be admixed with adetergent composition in granular, viscous liquid, paste or gel form.The resulting mixture may be used directly in the washing process,particularly in an automatic dishwasher, or it may be incorporatedwithin a water-soluble packet, for easy and convenient dispensing. Inthis case the water soluble resin is being used as a means to bind theenzyme to its matrix. This method of preparing the ribbons also suffersfrom the shortcoming that two or more reacting substances cannot bedispersed in the same film as they would interact with each other anddegrade.

[0010] U.S. Pat. No. 6,378,274 discloses a process for producing athermoformed package of the type comprising the steps of placing a firstsheet of formable film over a forming die having a cavity, moulding thefilm into the cavity thereby forming a recess in the film, placing acomposition in the thus formed recess, and sealing a second sheet offilm across the recess to close the package. In particular, the priorart relates to such a process for producing a water-soluble packagecontaining a detergent composition. The disclosure is restricted thermoformed packages formed out of a combination of soluble and insolublefilms. It also needs pre formed films to be operated on offlineequipment for packaging applications thereby making the process ofincorporating the materials within the films very complex and requiringexpensive equipment.

[0011] Patent No. EP 0493553 relates to a containerization system and tocontainers which are particularly suitable for storing, packaging andtransporting toxic or hazardous products, such as agriculturalchemicals. The containerization system comprises the chemical in theform of a gel, which is contained within a water soluble orwater-dispersible bag. This EP '553 has limitations as it is restrictedto toxic products that can be converted into gels and then packaging ofgel into a WSF bag.

[0012] Patent No. EP 0347220B1 relates to a package comprising e.g. aliquid chemical or a chemical dissolved or dispersed in an organicliquid contained in an envelope of water-soluble or water dispersiblematerial and having a water-soluble or water dispersible seal. Thepatent also provides a process for the preparation of a packageaccording to the invention which comprises heat sealing the envelopematerial to obtain a water dispersible or, preferably, a water solubleheat seal. This prior art specifically discusses packaging of pesticidesby means of an efficient heat seal system into a container.

[0013] Patent GB 2244258B relates to a package comprising hazardouschemical dissolved or dispersed in a liquid or gel which is contained inan envelope of water-soluble or water-dispersable material. The patentseeks to provide a new container system for agrochemicals which is safeto handle. This patent also provides a package which comprises ahazardous chemical dissolved or dispersed in a liquid or gel containedin a water-soluble or water-dispersible laminated film. There is alsodiscussed the delivery of toxic and hazardous materials by means ofplain and laminated soluble sachets.

[0014] It would be evident from the above state of the art that none ofthe prior art teach or provide for delivery of the encased, laminated orpackaged material in precise quantities. It is therefore thelong-standing need of industry to develop efficient and cost effectivestable embedded WSFs for controlled dosing in diverse applications andespecially to embed a wide variety of substances avoiding interactionwith each other within films. Further the need for carriers that canselectively carry combination of materials with dissimilar propertiessuch as miscible/in-miscible, hydrophobic/hydrophilic ingredientscontinues to elude the industry.

OBJECT OF THE INVENTION

[0015] The main object of the present invention is to provide stablewater soluble film system having embedded/entrapped actives and to aprocess for the manufacture of such stable water soluble films fordiverse applications, in which a variety of substances such asdetergents, enzymes, softeners, perfumes, pesticides, fungicides,pigments, hazardous chemicals, active agents for cleaning laundry,dishes, floorings, walls, furniture etc., and the like areembedded/entrapped singly or in combination for delivering them inprecise and desired dosages.

[0016] Another object of the present invention is to provide an offlineprocess for the manufacture of stable water soluble films for diverseapplications, in which a variety of substances such as detergents,enzymes, softeners, perfumes, pesticides, fungicides, pigments,hazardous chemicals, active agents for cleaning laundry, dishes,floorings, walls, furniture etc., and the like are embedded/entrappedsingly or in combination for delivering them in precise and desireddosages.

[0017] Another object of the invention is to provide a process ofentrapping absorbent materials such as fluff, pulp and the like withinWSFs.

[0018] It is yet another object of the invention to disperse diversenon-water-soluble materials on the surface and within WSFs.

[0019] Yet another object of the present invention is to provide aprocess for manufacture of multi-layered WSF to selectively entrapinteracting/non-interacting materials.

[0020] Yet another object of the present invention is to provide aprocess for manufacture of multi-layered WSF to selectively entrapcombination of materials with similar and/or dissimilar properties.

[0021] It is yet another object of the invention to provide a process ofmanufacturing of WSFs with materials embedded in selective areas of theWSFs in desired shapes.

[0022] It is yet another object of the invention to provide WSFs fordiverse applications, in which a variety of substances such asdetergents, enzymes, softeners, perfumes, pesticides, fungicides,pigments, hazardous chemicals, active agents for cleaning laundry,dishes, floorings, walls, furniture etc., and the like are embedded fordelivering them in precise and desired quantities.

[0023] It is yet another object of the invention to provide a processfor the manufacture of WSFs exploiting the various embodiments of theinvention using a wide range of raw materials including polyvinylalchohol copolymer ionomers, polyvinyl alchohol homopolymer.non-ionomeric poly vinyl alchohol polymer, polymethacrylate., polyvinylalchohol, polyacrylamide, polymethacrylamide, polyacrylic acid,polymethacrylic acid, polyethyleneglycol, polyvinylpyrrolidone,proteinaceous binders such as gelatin modified gelatins such asphthaloyl gelatin, polysaccharides, such as starch, gum arabic anddextrin and water-soluble cellulose derivatives.

[0024] It is yet another object of the invention to provide a processfor the manufacture of WSFs with the options to use a range of linerssuch as paper, film, foil or fabric, preferably of film, more preferablyof polyester film. The film liners may be plain, metalised, embossed,gloss or matte depending upon the desired end product parameters. Paperliner can be plain, embossed, gloss, matte, extrusion coated laminatedor release coated. Fabrics made of cotton or synthetic yarns, solutioncoated, plain, embossed, gloss, matte, extrusion coated or laminated maybe used as liner dependant dependent upon the desired end productproperties. Foils made of steel, aluminum, copper or mixture thereof,more preferably aluminum foil, plain, embossed, gloss, matte, extrusioncoated laminated or release coated. A liner may be made of a combinationof any or all of the above materials. A liner may be used for single useor may be used for multiple uses.

SUMMARY OF THE INVENTION

[0025] Thus according to one aspect of the present invention there isprovided a WSF system comprising at least one active material embeddedand/or entrapped at selected concentrations and depths/dispositionstherein such that said active material thus embedded/entrapped could bedelivered at precisely regulated dosages.

[0026] According to another aspect the present invention is directed toa process for the manufacture of embedded/entrapped water-soluble film(WSF) system comprising:

[0027] i) providing the formulation of said WSF with or without linermaterial

[0028] ii) subjecting the said WSF to casting wherein at least onedesired active material is embedded/entrapped prior to and/or after thesaid casting of the WSF.

[0029] According to another aspect the present invention is directed toa process for the manufacture of embedded/entrapped water-soluble film(WSF) system using a casting liner or a conveyor comprising:

[0030] i) Mixing of the formulation of WSF;

[0031] ii) casting of at least one WSF at at least one casting head;

[0032] iii) metering of the cast film at the respective casting head,wherein said active material to be embedded is added with the WSF priorto casting and/or at least during casting;

[0033] iv) smoothening of the at least one film thus formed; and

[0034] v) drying of the WSF.

[0035] According to another aspect the present invention is directed toa process comprising the steps of dispersing of material to be embeddedon said cast WSF prior to the step of smoothing at anyone or more ofsaid casting heads for casting of the films. The WSF films thus embeddedare wound and retained.

[0036] According to another aspect the present invention is directed toa process comprising:

[0037] i) unwinding a pre-formed WSF from an unwinder and guiding itthrough guide rolls to meet the WSF with said embedded materials forfurther entrapping of the materials embedded; followed by

[0038] ii) guiding the multilayered WSF of step (i) through hot/chilldevice for rewinding or splitting.

[0039] According to another aspect the present invention is directed tousing a casting conveyor without liner comprising:

[0040] i) casting of WSF with embedded material the temperature rangemaintained from 10° C. to 95° C., preferably 13° C. to 90° C., morepreferably 15° C. to 85° C.;

[0041] ii) metering of the cast film at casting head;

[0042] iii) smoothening of the film with the embedded materials at theprimary station;

[0043] iv) drying of the WSF from step (i), the temperature range in thedryers ranging from 50° C. to 250° C., preferably from 60° C. to 200°C., more preferably from 55° C. to 170° C.;

[0044] v) rewinding of the WSF.

[0045] According to yet another aspect the present invention is directedto a process using a Casting WSF on a liner comprising:

[0046] i) providing a liner for the formation of WSF with or withouttreating/coating;

[0047] ii) casting of WSF with embedded material, the temperature rangeof the batch solution maintained from 10° C. to 95° C., preferably from13° C. to 90° C., more preferably from 15° C. to 85° C.;

[0048] iii) metering of the cast film at casting head;

[0049] iv) smoothening of the film with the embedded material at primarystation, the percentage of solid content maintained in the range of 3%to 85%, preferably in the range of 4% to 70%, more preferably in therange of 5% to 65%;

[0050] v) drying of the WSF, the temperature range in the dryersmaintained from 50° C. to 250° C., preferably from 60° C. to 200° C.,more preferably 55° C. to 170° C.;

[0051] vi) casting of WSF with or without the material to be embedded atsecondary/tertiary subsequent casting head(s);

[0052] vii) drying of the WSF, the temperature range in the seconddryers maintained from 50° C. to 200° C., preferably 60° C. to 160° C.,more preferably 55° C. to 140° C.;

[0053] viii) guiding the multi-layered WSF through hot/chill device forrewinding or splitting.

[0054] According to a further aspect the present invention is directedto a process using a spraying method comprising:

[0055] i) unwinding of the liner for the formation of WSF and/or aconveyor is provided.

[0056] ii) optional coating of the liner via a primer coating station;

[0057] iii) casting of WSF with material to be embedded at a primarycasting head, the temperature range of the batch solution maintainedfrom 10° C. to 95° C., preferably 13° C. to 90° C., more preferably 15°C. to 85° C.;

[0058] iv) metering of the cast film at a casting head;

[0059] v) executing a controlled dosing by spraying of pre-measuredmaterial to be embedded by primary sprayer;

[0060] vi) smoothening of the film with the embedded material at aprimary station;

[0061] vii) drying of the WSF at a dryer, the temperature range in thedryers maintained in the range of 50° C. to 250° C., preferably from 60°C. to 200° C., more preferably 55° C. to 170° C.;

[0062] viii) casting of WSF with or without the material to be embeddedat secondary/tertiary subsequent casting head(s);

[0063] ix) drying of the WSF, the temperature range in the second dryermaintained 50° C. to 200° C., preferably 60° C. to 160° C., morepreferably 55° C. to 140° C.;

[0064] x) guiding the multilayered WSF through hot/chill cylinder forrewinding or splitting.

[0065] According to another aspect the present invention is directed toa process using a Secondary application on partially formed filmcomprising:

[0066] i) unwinding of the liner for the formation of WSF and/orproviding a conveyor;

[0067] ii) optional coating of the liner via a primer coating station;

[0068] iii) casting of WSF with material to be embedded at primarycasting head, the temperature range of the batch maintained in the rangeof 10° C. to 95° C., preferably 13° C. to 90° C., more preferably 15° C.to 85° C.;

[0069] iv) metering of the cast film at casting head;

[0070] v) smoothening of the film with the embedded material at primarystation, drying of the WSF, the temperature range in the dryersmaintained in the range of 50° C. to 250° C., preferably from 60° C. to200° C., more preferably 55° C. to 170° C.;

[0071] vi) executing a controlled dosing by spraying of pre-measuredmaterial to be embedded by secondary disperser;

[0072] vii) smoothening of the film with the embedded material atsecondary station;

[0073] viii) casting of WSF with or without the material to be embeddedat secondary/tertiary subsequent casting head(s);

[0074] ix) drying of the WSF, the temperature range in the seconddryers) maintained in the range of 50° C. to 200° C., preferably 60° C.to 160° C., more preferably 55° C. to 140° C.;

[0075] x) guiding the multilayered WSF through hot/chill cylinder forrewinding or splitting. Optionally offline or online splitting betweenthe WSF film and the liner.

[0076] According to another aspect the present invention is directed toonline entrapment comprising:

[0077] i) unwinding of the liner for the formation of WSF and/orproviding a conveyor;

[0078] ii) optional coating of the liner via a primer coating station;

[0079] iii) casting of WSF with material to be embedded at primarycasting head the temperature range maintained 10° C. to 95° C.,preferably 13° C. to 90° C., more preferably 15° C. to 85° C.;

[0080] iv) metering of the cast film at casting head;

[0081] v) smoothening of the film with the embedded material at primarystation;

[0082] vi) drying of the WSF, the temperature range in the dryersmaintained in the range of 50° C. to 250° C., preferably from 60° C. to200° C., more preferably from 55° C. to 170° C.;

[0083] vii) casting of WSF with or without the material to be embeddedat secondary/tertiary subsequent casting head(s);

[0084] viii) drying of the WSF, the temperature range in the seconddryers maintained from 50° C. to 200° C., preferably 60° C. to 160° C.,more preferably 55° C. to 140° C.;

[0085] ix) unwinding of a pre-formed WSF from an unwinder and guiding itthrough the guide rolls to meet the WSF, with embedded material forentrapping of materials embedded.

[0086] Preferably, in the above process of the invention, the materialsof the WSF formulation is taken in a batch reactor and mixed intimatelyto ensure complete dissolution in the desired solvent. As would beevident from the above various possible embodiments of the process canbe followed.

[0087] In one of the embodiments of this of this invention the materialsto be embedded in the WSF are added to the batch solution and mixedthoroughly before feeding it to the casting head for further processing.The materials that can be taken into the batch mixing are selected fromthose that are water-soluble, sheer insensitive, temperature resistant,like certain agrochemicals, pesticides, insecticides, softners,surfactants, perfumes for detergent and laundry industry, disinfectants,de-odorizing liquids, etc.

[0088] In another embodiment of this invention the materials to beembedded in the WSF may optionally be introduced in the process at theprimary, secondary, tertiary and subsequent sprayers and or at thesecond or subsequent casting heads fed from second and/or subsequentbatch mixers.

[0089] In another embodiment of the present invention the materials tobe embedded is dispensed in between incoming cured or uncured WSFs

[0090] In another embodiment of the present invention the process maybecarried out with the aid of a self-rolling conveyor.

[0091] In yet another embodiment of the present invention the processmaybe carried out with the aid of a casting liner.

DETAILED DESCRIPTION IN RELATION TO ACCOMPANYING FIGURES

[0092] The details of the invention its objects and advantages areexplained hereunder in greater details in relation to non-limitingexemplary illustrations given in FIGS. 1-4

[0093] The explanation to the part numbers in FIG. 1 is given below:

[0094]1 Conveyor; 2 Guide Roll; 3 Batch Mix; 4 Primary Casting Head; 5Primary Sprayer; 6 Smoothening Rolls; 7 Dryer; 8 Secondary Sprayer; 9Secondary Casting Head; 10 Dryer; 11 Tertiary Sprayer; 12 Disperser forEntrapment; 13 Guide Roll; 14 Chilling Cylinder; 15 Rewinder; 16 GuideRolls; 17 Unwinder; 18 Smoothening Rolls; 19 Batch Mix; 20 Nip Roll;

[0095] Accordingly as illustrated in FIG. 1 the process comprises of thefollowing steps:

[0096] 1. Batch Mixing of the formulation of WSF and optionally thematerial to be embedded;

[0097] 2. Casting of WSF with or without the material to be embedded atprimary casting head;

[0098] 3. Metering of the cast film at casting head;

[0099] 4. Optionally dispersing of material to be embedded by primarysprayer;

[0100] 5. Smoothening of the film with or without the embedded materialsat the primary station;

[0101] 6. Drying of the WSF from step 2;

[0102] 7. Optional spraying of material to be embedded using a secondarysprayer;

[0103] 8. Smoothening of the film with or without the embedded materialsat the secondary station;

[0104] 9. Drying of the WSF from step 7;

[0105] 10. Casting of WSF with or without the material to be embedded atsecondary casting head;

[0106] 11. Optional spraying of material to be embedded by a tertiarydisperser;

[0107] 12. Rewinding of the WSF;

[0108] 13. Optionally as a post-step 11 step unwind a pre-formed WSFfrom an unwinder and guiding it through the guide rolls to meet the WSFfrom step 11 for entrapping of materials to be embedded;

[0109] 14. Guide the multilayered WSF of step 13 through hot/chillcylinder for rewinding or splitting;

[0110] Optionally the steps 1 to 14 may also be carried out on a castingliner (FIG. 1) or a conveyor (FIG. 2).

[0111] The invention and the various embodiments are further explainedhereunder in relation to the accompanying figures:

[0112] Casting Conveyor without Liner [FIG. 1]

[0113] This process comprises of the following:

[0114] 1. Casting of WSF on (1) at (4) with embedded material in thebatch mix. The temperature range of the batch solution is in between mayvary from around 10° C. to around 95° C., preferably around 13° C. toaround 90° C., preferably around 15° C. to around 85° C.

[0115] 2. Metering of the cast film at casting head.

[0116] 3. Smoothening of the film with the embedded materials at theprimary station (6).

[0117] 4. Drying of the WSF from step 1 at (7). The temperature range inthe dryers may vary from around 50° C. to around 250° C., preferablybetween around 60° C. to around 200° C., more preferably between around55° C. to around 170° C. Rewinding of the WSF at (15).

[0118] Casting WSF on a Liner (FIG. 2)

[0119] The explanation to the part numbers in FIG. 2 is given below:

[0120]25 Unwinder of “Carrier Web”; 26 Primer Coating; 27 Batch Mix; 28Primary Casting Head; 29 Primary Sprayer; 30 Smoothening Roll; 31 Dryer;32 Secondary Sprayer; 33 Secondary Casting Head; 34 Dryer; 35 TertiarySprayer; 36 Disperser for Entrapment; 37 Guide Roll; 38 ChillingCylinder; 39 Rewinder; 40 Guide Rolls; 41 Unwinder; 42 SmootheningRollers; 43 Batch Mix; 44 Nip Roll;

[0121] This process comprises of the following:

[0122] 1. Unwinding of the liner at (25) for the formation of WSF whichcan be optionally treated or untreated and coated or uncoated. Linerscan be of paper, film, foil or fabric, preferably of film, morepreferably of polyester film. The films can be in the range of 2 micronsto 500 microns, preferably in the range of 10 microns-300 microns, morepreferably in the range of 12 microns-250 microns. The film liner may beplain, metallised, embossed, gloss, matte, extrusion coated laminated orrelease coated depending on the desired characteristics of the endproduct. Paper Liner are also used for production of WSF film. Paperliners that accept temperatures needed for production of WSF, GSM (Gramsper sq meter—the standard for measuring weight of paper) may be in therange of around 7 gms to around 500 gms, preferably a range of around 20gm to around 300 gms, more preferably in the range of around 60 gm toaround 180 gms. The paper liner may be plain, embossed, gloss, matte,extrusion coated laminated or release coated depending on the desiredcharacteristics of the end product. Fabrics made of cotton or syntheticyarns, solution coated, plain, embossed, gloss, matte, extrusion coatedor laminated may be used as liner based on the desired end productproperties.

[0123] 2. Optional coating of the liner via a primer coating station(26).

[0124] 3. Casting of WSF on (25) at (28) with embedded material in thebatch mix. The temperature range of the batch solution may be around 10°C. to around 95° C., preferably around 13° C. to around 90° C., morepreferably around 15° C. to around 85° C.

[0125] 4. Metering of the cast film at casting head.

[0126] 5. Smoothening of the film by (30) with the embedded material atprimary station.

[0127]  The percentage of solid content may be in the range of around 3%to around 85%, preferably in the range of around 4% to around 70%, morepreferably in the range of around 5% to around 65%

[0128] 6. Drying of the WSF from step 3 at (31). The temperature rangein the dryers may be set from around 50° C. to around 250° C.,preferably from around 60° C. to around 200° C., more preferably around55° C. to around 170° C. The temperature range of the batch solution mayvary from around 10° C. to around 95° C., preferably around 13° C. toaround 90° C., more preferably around 15° C. to around 85° C.

[0129] 7. Casting of WSF with or without the material to be embedded atsecondary/tertiary subsequent casting head(s) (33).

[0130] 8. Drying of the WSF from step 7 at (34). The temperature rangein the second dryers (34) may be from around 50° C. to around 200° C.,preferably around 60° C. to around 160° C., more preferably around 55°C. to around 140° C.

[0131] 9. The multi-layered WSF of step 8 is guided through hot/chillcylinder (38) for rewinding or splitting at (39).

[0132] Spraying Method (FIG. 2)

[0133] This process comprises of the following

[0134] 1. Unwinding of the liner at 25 for the formation of WSF.Optionally a conveyor can be used.

[0135] 2. Optional coating of the liner via a primer coating station(26).

[0136] 3. Casting of WSF with material to be embedded at primary castinghead (28). The temperature range of the batch solution may vary fromaround 10° C. to around 95° C., preferably around 13° C. to around 90°C., more preferably around 15° C. to around 85° C.

[0137] 4. Metering of the cast film at casting head.

[0138] 5. Spraying of pre-measured material to be embedded by primarysprayer (29).

[0139] 6. Smoothening of the film with the embedded material at primarystation (30).

[0140] 7. Drying of the WSF from step 5 at dryer (31). The temperaturerange in the dryers may be set from 50° C. to around 250° C., preferablyfrom around 60° C. to around 200° C., more preferably around 55° C. toaround 170° C.

[0141] 8. Casting of WSF with or without the material to be embedded atsecondary/tertiary subsequent casting head(s) (33).

[0142] 9. Drying of the WSF from step 8 at dryer (34). The temperaturerange in the second dryer (34) may be from around 50° C. to around 200°C., preferably around 60° C. to around 160° C., more preferably around55° C. to around 140° C.

[0143] 10. The multilayered WSF of step 8 is guided through hot/chillcylinder (38) for rewinding or splitting at (39).

[0144] Secondary Application on Partially Formed Film [FIG. 2]

[0145] This process comprises of

[0146] 1. Unwinding of the liner at (25) for the formation of WSF.Optionally a conveyor can be used.

[0147] 2. Optional coating of the liner via a primer coating station(26).

[0148] 3. Casting of WSF with material to be embedded at primary castinghead (28). The temperature range of the batch solution may vary fromaround 10° C. to around 95° C., preferably around 13° C. to around 90°C., more preferably around 15° C. to around 85° C.

[0149] 4. Metering of the cast film at casting head.

[0150] 5. Smoothening of the film with the embedded material at primarystation (30).

[0151] 6. Drying of the WSF from step 5 at dryer (31). The temperaturerange in the dryers may be set from 50° C. to around 250° C., preferablyfrom around 60° C. to around 200° C., more preferably around 55° C. toaround 170° C.

[0152] 7. Spraying of pre-measured material to be embedded by secondarydisperser (32).

[0153] 8. Smoothening of the film with the embedded material atsecondary station (42).

[0154] 9. Casting of WSF with or without the material to be embedded atsecondary/tertiary subsequent casting head(s) (33).

[0155] 10. Drying of the WSF from step 9 at dryer (34). The temperaturerange in the second dryers (34) may be from around 50° C. to around 200°C., preferably around 60° C. to around 160° C., more preferably around55° C. to around 140° C.

[0156] 11. The multilayered WSF of step 9 is guided through hot/chillcylinder (38) for rewinding or splitting at (39). Optionally offline oronline splitting between the WSF film and the liner can be done.

[0157] Online Entrapment Method [FIG. 21]

[0158] The process comprises of the following:

[0159] 1. Unwinding of the liner at (25) for the formation of WSF,optionally a conveyor can be used.

[0160] 2. Optional coating of the liner via a primer coating station(26).

[0161] 3. Casting of WSF with material to be embedded at primary castinghead (28). The temperature range of the batch solution may vary fromaround 10° C. to around 95° C., preferably around 13° C. to around 90°C., more preferably around 15° C. to around 85° C.

[0162] 4. Metering of the cast film at casting head.

[0163] 5. Smoothening of the film with the embedded material at primarystation (30).

[0164] 6. Drying of the WSF from step 5 at dryer (31) The temperaturerange in the dryers may vary from around 50° C. to around 250° C.,preferably from around 60° C. to around 200° C., more preferably fromaround 55° C. to around 170° C.

[0165] 7. Casting of WSF with or without the material to be embedded atsecondary/tertiary subsequent casting head(s) (33).

[0166] 8. Drying of the WSF from step 7 at dryer (34). The temperaturerange in the second dryers (7) may be from around 50° C. to around 200°C., preferably around 60° C. to around 160° C., more preferably around55° C. to around 140° C.

[0167] 9. Unwinding of a pre-formed WSF from an unwinder (41) andguiding it through the guide rolls (40) to meet the WSF from step 8 forentrapping of materials to be embedded. Both the liners along with WSFfilm, which may be semi-cured WSF and the entrapments, may remain in theroll form or sheet form in its original construction, stripping fromcasting liner can be done immediately or after an self-curing ageingperiod ranging from around 1 hrs. to around 720 hrs., prior to splittingthe liners so as to deliver the final WSF product with entrappedmaterials.

[0168] 10. If desired the multi-layered WSF of step 9 may be guidedthrough hot/chill cylinder (38) for rewinding or splitting at (39).Optionally offline or online splitting between the WSF film and theliner can be done

[0169] The process described above offers various possibilities for themanufacture of WSFs with entrapped materials either on a liner or aconveyor. Some of the product options the may be exercised are asfollows:

[0170] H/E/H

[0171] H/E/C

[0172] H/E/H/E/H . . . n times

[0173] C/E/C/E/ . . . n times

[0174] C/E/C/E/C . . . n times

[0175] C/E/C . . . n times

[0176] L/UC/E/UH/E . . . n times

[0177] L/UH/E/UH/E . . . n times

[0178] L/UC/E/UC/E . . . n times

[0179] L/UC/E/H/L/E . . . n times

[0180] L/UH/E/H/L/E . . . n times

[0181] L/UC/E/C/L/E . . . n times

[0182] Where

[0183] U=Uncured; H=Hot Water Soluble Film; C=Cold Water Soluble Film

[0184] E=Embedded Material; L=Liner

[0185] and the value of “n” is decided based on the application of thefinal multilayered embedded WSF.

[0186] The above sequence may be repeated in multiple layers as per therequirements of the end use of the multiply embedded WSFs. Further thisprocess also allows the manufacture of multilayered embedded WSF usingcombinations of Cold WSFs and Hot WSFs in various sequences. It alsoprovides the options of using cured/uncured films of CWSFs and HWSFs inany desired sequences

[0187] Dimples or other embossed or patterned designs can be createdduring entrapment by using such designed male/female rollers (46,51Sheet No. 3) or rollers (60,61 Sheet No. 4). In case of casting on linermethod both the liners along with WSF film, semi-cured WSF and theentrapments may remain in roll form or sheet form in its originalconstruction, stripping from casting liner can be done immediately orafter an self curing aging period ranging from around 1 hrs to around720 hrs., prior to splitting the liners so as to deliver the final WSFfilm with entrapped materials.

[0188] Certain materials such as highly alkaline or highly acidicmaterials may react adversely if added in the batch mix process or ifsprayed before the gelling process or before the film forming processand may therefore necessitate the use of entrapment method forincorporating such materials. Certain liquids like oil based perfumes,aromas, softening agents, cleaning agents etc or solvent based aromas,softening agents, cleaning agents etc may be entrapped more efficientlywith entrapment method disclosed in this invention.

[0189] Offline Entrapment Method

[0190] The process to incorporate such sensitive materials describedabove comprises of the following:

[0191] Vertical Entrapment Method (FIG. 3).

[0192] The explanation to the part numbers in FIG. 3 is given below:

[0193]45 Unwinder; 46 Affixing Roller; 47 Guide Roll; 48 Disperser forVertical Entrapment; 49 Guide Roll; 50 Unwinder; 51 Affixing Roller; 52Rewinder;

[0194] 1. Unwinding of the WSF films (45) and (50) with or withoutliner.

[0195] 2. Dispensing of the embodiment at (48) in between two affixingguide rollers (47 & 49).

[0196] 3. Affixing of the WSF films from step 2 at the affixing rollers(46 & 51).

[0197] 4. Rewinding in roll form or sheet form or fan-fold form.Optionally the film can be with or without casting liners. The castingliners can be stripped immediately or after aging period of around 1 toaround 720 hrs. or can be supplied all together and the end user may beinformed to strip the casting liner before use. The entrapped film canalso be slit in ribbons, tapes, perforated sheets, perforated tapes,perforated ribbons or cut sheets of any size.

[0198] Such a process offers various process and product options suchas:

[0199] 1. Entrapped material in WSF With or without carrier.

[0200] 2. Entrapped material in WSF in Roll form or pouch form

[0201] 3. Entrapped material in WSF in Roll form with perforates

[0202] 4. Entrapped material in WSF in Sheet form with multiple pouches

[0203] 5. All above Entrapped material in WSF with casting liner for theconsumer to remove immediately or after aging period of around 1 hr toaround 720 hrs.

[0204] Some of the product options the may be exercised are as follows:

[0205] H/E/H

[0206] H/E/C

[0207] H/E/H/E/H . . . n times

[0208] C/E/C/E . . . n times

[0209] C/E/C/E/C . . . n times

[0210] C/E/C . . . n times

[0211] L/UC/E/UH/E . . . n times

[0212] L/UH/E/UH/E . . . n times

[0213] L/UC/E/UC/E . . . n times

[0214] L/UC/E/H/L/E . . . n times

[0215] L/UH/E/H/L/E . . . n times

[0216] L/UC/E/C/L/E . . . n times

[0217] Where

[0218] U=Uncured; H=Hot Water Soluble Film; C=Cold Water Soluble Film

[0219] E=Embedded Material; L=Liner

[0220] and the value of “n” is decided based on the application of thefinal multilayered embedded WSF.

[0221] The above sequence may be repeated in multiple layers as per therequirements of the end use of the multiply embedded WSFs. Further thisprocess also allows the manufacture of multilayered embedded WSF usingcombinations of Cold WSFs and Hot WSFs in various sequences. It alsoprovides the options of using cured/uncured films of CWSFs and HWSFs inany desired sequences

[0222] Horizontal Entrapment Method (FIG. 4).

[0223] The explanation to the part numbers in FIG. 4 is given below:

[0224]55 Unwinder; 56 Guide Roll; 57 Disperser for HorizontalEntrapment; 58 Guide Roll; 59 Unwinder; 60 Affixing Roller; 61 AffixingRoller; 62 Rewinder; 63 Spillage Controller Knife;

[0225] 1. Unwinding of the WSF films (59) and (55) with or withoutliner.

[0226] 2. Dispensing of the embodiment at (57) in between two affixingguide rollers (58 & 56).

[0227] 3. Affixing of the WSF films from step 2 at the affixing rollers(60 & 61).

[0228] 4. Rewinding in roll form or sheet form or fan-fold form.Optionally the film can be with or without casting liners. The castingliners can be stripped immediately or after aging period of around 1 hrto around 720 hrs. or can be supplied all together and the end user maybe informed to strip the casting liner before use. The entrapped filmcan also be slit in ribbons, tapes, perforated sheets, perforated tapes,perforated ribbons or cut sheets of any size.

[0229] Such a process offers various process and product options suchas:

[0230] 1. Embedded/entrapped material in WSF With or without carrier.

[0231] 2. Embedded/Entrapped material in WSF in Roll form or pouch form

[0232] 3. Embedded/Entrapped material in WSF in Roll form withperforates

[0233] 4. Embedde/Entrapped material in WSF in Sheet form with multiplepouches

[0234] 5. All above Embedded/Entrapped materials in WSF with castingliner for the enduser to remove after aging period of around 1 hr toaround 720 hrs.

[0235] In the above options the WSF film may be pre-embedded and usedfor the manufacture of the above product options.

[0236] In yet other embodiment of the invention, materials that arestable in hot water conditions may be introduced into Hot Water SolubleFilms (HWSF) and those that are sensitive to cold conditions can beincorporated in Hot or Cold Water Soluble Films (CWSF).

[0237] Applications of the Process Options

[0238] The invention with various embodiments are now furtherillustrated with a few non-limiting Examples:

EXAMPLE I

[0239] Embedding of Actives such as Piian Liquid in WSF

[0240] Piian is a water dispersable deodorizer which is commerciallyavailable from Piian Systems, USA. Piian was added to the pre-mixed WSFformulation batch and stirred for 6 hours. This was followed by a periodof another 6 hours with continuous slow stirring of the solution. Thesolution was then casted on a continuous casting line. It was then driedand spilt. Several samples of varying compositions were made toincorporate 10% Piian to 90% in WSFs.

[0241] The Grammage per Square Meter (GSM) for the Piian incorporatedWSF measured as per IS1060 is represented as (A).

[0242] A reference WSF without the incorporation of Piian was preparedunder identical conditions. The GSM of this reference sample isrepresented as (B). The Piian loaded in the WSF is therefore A−B=C.

[0243] Strips of 10×10 cms were cut from the material WSF loaded withPiian.

[0244] Following are the characteristics of the WSF strips loaded withPiian.: Piian Loaded film = 30.5 GSM (±½ Gm) Loading of Piian= 5 GSMFilm thickness of Piian loaded WSF = 28 microns GSM of the Referencefilm without Piian = 26 gms.(±1 gm)

[0245] Following are test results of reference WSF and Piian loaded WSFTensile Strength of the reference film (kg/cm²)Dir-I = 380.74 TestMethod - ASTM D-883 Dir-II = 382.67 Test Method - ASTM D-883 YoungModulus (kg/mm²)Dir-I = 13.19 Test Method - ASTM D-882 Dir-II = 8.14Test Method - ASTM D-882 Elongation(%) (kg/cm²)Dir-I = 259.27 TestMethod - ASTM D-882 Dir-II = 252.90 Test Method - ASTM D-882 PunctureResistance (Ozs. Inches/Tear Inch) = 270.00 Test Method - IS-1060

[0246] Tensile Strength of the Piian Load WSF (kg/cm²)Dir-I = 329.5 TestMethod - ASTM D-883 Dir-II = 381.1 Test Method - ASTM D-883 YoungModulus (kg/mm²)Dir-I = 7.38 Test Method - ASTM D-882 Dir-II = 11.81Test Method - ASTM D-882 Elongation(%) (kg/cm²)Dir-I = 252.36 TestMethod - ASTM D-882 Dir-II = 291.50 Test Method - ASTM D-882 PunctureResistance (Ozs. Inches/Tear Inch) = 225.00 Test Method - IS-1060Dissolution in seconds = 86 secs at 30 C. Breaking of the film = 3.14secs at 30 C.

[0247] The film properties of the Piian laoded WSF, together with theuniform dispersion of the Piian in the WSF illustrates that Piian can bedelivered in precise quantities by incorporating it in the WSF using theprocess disclosed in the invention.

[0248] In one of the variants of the process described in thisinvention, pre-dissolved enzymes may be mixed in a WSF formulation and acontrolled casting on a preformed substrate/liner based WSF film ispossible. Alternatively two pre-formed substrate based WSF films may beused. A water-based enzyme may be loaded to precisely fill the center ofthe two films. The water based enzyme helps to affix the two filmssubstrates so that the enzymes are sandwiched in between the filmsthereby resulting in an enzyme loaded WSF. The two substrates can thenbe stripped off after appropriate ageing.

[0249] Enzymes in precise quantities can be incorporated in singly ormulti-layered WSFs by the process described in this invention so thatthe processor or the user does no inhalation of the enzyme. The enzymeembedded WSF can be incorporated into detergent formulations or added towashing medium in a machine or a washing vessel such as a bucket toensure that the precise dosage of enzymes are added at the point ofapplication.

EXAMPLE II

[0250] Incorporation of Large Particles in WSFs

[0251] Non-soluble Acrylic resins (72-75 microns) were dispersed intocold water-based solutions to form a high viscous dispersion. The liquiddispersion was dropped in between two films through a motorized valvecontrolled slot nozzle to have a margin at the end of the webs, therebynot allowing the dispersion to ooze out from the sides. Cold water wasused as the solvent. Both the WSFs used were Hot Water Solubleformulations. In this process the Hot Water Soluble Films. Do not getaffected by cold-water dispersion and therefore remain entrapped tillthe acrylic entrapped film passes through the dried and reaches therewinder. Typically the film is split from its casting liner after anappropriate aging period.

[0252] The properties of the acrylic incorporated films were: AcrylicLoaded GSM = 60 GSM (±½ Gm) Microns of Acrylic loaded film 140 micronsBase films GSM = 58 GSM (±1 gm) Weight of Acrylic Entrapping = 2 GSM

[0253] Similarly following are test results of reference WSF and Acrylicresin loaded WSF Tensile Base film (kg/cm²)Dir-I = 380.74 Test Method -ASTM D-883 Dir-II = 382.67 Test Method - ASTM D-883 Young Modulus(kg/mm²)Dir-I = 13.19 Test Method - ASTM D-882 Dir-II = 8.14 TestMethod - ASTM D-882 Elongation(%) (kg/cm²) Dir-I = 259.27 Test Method -ASTM D-882 Dir-II = 252.90 Test Method - ASTM D-882 Puncture Resistance(Ozs. Inches/Tear Inch) = 270.00 Test Method - IS-1060

[0254] Tensile Acrylic Entrapped film (kg/cm²)Dir-I = 80.69 TestMethod - ASTM D-883 Dir-II = 83.46 Test Method - ASTM D-883 YoungModulus (kg/mm²)Dir-I = 2.79 Test Method - ASTM D-882 Dir-II = 3.25 TestMethod - ASTM D-882 Elongation(%) (kg/cm²)Dir-I = 229.5 Test Method -ASTM D-882 Dir-II = 206.7 Test Method - ASTM D-882 Puncture Resistance(Ozs. Inches/Tear Inch) = 180.0 Test Method - IS-1060 Dissolution offilm in seconds = 47 secs at 30 C. Breaking of the film = 3.75 secs at30 C.

[0255] The WSF characteristic with the hydrophobic polymer indicatesthat the process disclosed in the invention can be effectively used toembed any hydrophobic materials of diverse shapes and sizes within a WSFmatrix.

[0256] Also this application shows the possibility of using two hotwater soluble films or a combination thereof, taking advantage of thehydrophilic properties. This application also shows the advantage ofusing casting liners.

EXAMPLE III

[0257] Films incorporating water insoluble fine particles

[0258] The performance of the films based on water insoluble fineparticles were prepared by the process described in this invention. Fineparticle sized iron oxide (5-10 Microns) was dispersed in water basedformulations to form a high viscous dispersion. The liquid dispersionthus obtained was precisely dropped in between two films through amotorized valve controlled slot nozzle in such a manner that a marginwas available at the end of the webs, so as not to allow the dispersionto ooze out from the sides. In this case warm water at around 40° C. wasused to deliver the dispersion to between two Cold WSF webs.

[0259] The properties of the ferric oxide incorporated films were: GSMof Iron Oxide Loaded WSF = 73 GSM (±½ Gm) Thickness of Iron Oxide LoadedWSF = 55 microns GSM of reference WSF = 58 GSM (±1 gm) Weight of IronOxide Entrapping = 15 GSM

[0260] Tensile Strength of Entrapped film (kg/cm²)Dir-I = 325.87 TestMethod - ASTM D-883 Dir-II = 327.77 Test Method - ASTM D-883 YoungModulus (kg/mm²)Dir-I = 7.18 Test Method - ASTM D-882 Dir-II = 8.26 TestMethod - ASTM D-882 Elongation(%) (kg/cm²)Dir-I = 341.9 Test Method -ASTM D-882 Dir-II = 324.27 Test Method - ASTM D-882 Puncture Resistance(Ozs. Inches/Tear Inch) = 600 Test Method - IS-1060 Dissolution inseconds = 37 secs at 60 C. Breaking of the film = 19 secs at 60 C.

[0261] As illustrated in the earlier examples the material embeddedfilms have favorable film properties and cab be used for diverseapplication. This application provides possibilities of embeddingenvironmentally sensitive materials, wastes and toxic materials ofdiverse shapes, sizes and reactivities within an appropriate WSF Matrixin precise quantities for storage, transportation or disposal. Thismethod may also be used to embed powdered or granular materials of anyshapes or sizes such as pesticides, solid deodorants, disinfectants,uncoated enzymes, toxic products etc. which are to be delivered to theirpoint of application/action or storage.

[0262] These applications also clearly demonstrate the wide number ofproduct and process options using the methods disclosed in thisinvention.

1-52. (Cancelled).
 53. A water soluble film (WSF) system comprising atleast one water soluble film having at least one active material ofselective concentration and depth embedded therein such that said activematerial can be delivered in desired quantity.
 54. A water soluble filmsystem as claimed in claim 53 wherein said active materials are selectedfrom the group comprising detergents, enzymes, softeners, perfumes,pesticides, fungicides, active ingredients, dyes, pigments, hazardouschemicals, active agents for cleaning laundry, dishes, floorings, walls,furniture.
 55. A water soluble film system as claimed in claim 53comprising a removable liner for the water soluble film, for example theliner may be selected from material such as paper, film foil or fabric,such as polyester film and the film line material is preferably selectedfrom the group comprising plain, embossed, metalized, gloss, matte,extrusion coated laminated or release coated.
 56. A water soluble filmsystem according to claim 53 comprising a plurality of water solublefilms having active material embedded therein, and the films arepreferably soluble in a selected one of hot and cold water, for example,the system may comprise films that are soluble in cold water only, hotwater only or a combination of hot and cold water.
 57. A water solublefilm system as claimed in claim 53 wherein the films range from around 2microns to around 500 microns, preferably in the range of around 10microns to around 300 microns, more preferably in the range of around 12microns to around 250 microns.
 58. A process for the manufacture of awater soluble film system comprising the following steps: providing aformulation of said water soluble film; casting said formulation to forma water soluble film; embedding at least one desired active material insaid formulation of the said water soluble film prior to and/or aftercasting the said water soluble film; and drying the film with theembedded active material.
 59. A process as claimed in claim 58 furthercomprising the step of metering said water soluble film onto a castingconveyor or a liner at a casting head, smoothing the film with theembedded active material at a primary station, and stripping the watersoluble film from the conveyor or liner.
 60. A process as claimed inclaim 59 further comprising the step of stripping the water soluble filmfrom the liner immediately after drying or after a self-curing ageingperiod ranging from 1 hrs. to 720 hrs.
 61. A process as claimed in claim58 wherein the water soluble film with embedded active material has apercentage of solid content in the range of 3% to 85%, preferably in therange of 4% to 70%, more preferably in the range of 5% to 65%;
 62. Aprocess as claimed in claim 58 wherein casting is carried out at atemperature in the range from 10° C. to 95° C., preferably 13° C. to 90°C., more preferably 15° C. to 85° C.
 63. A process as claimed in claim58 wherein drying is carried out at a temperature in the range from 50°C. to 250° C., preferably from 60° C. to 200° C., more preferably from55° C. to 170° C.
 64. A process as claimed in claim 58 wherein activematerial is added to the formulation of the water soluble film systemprior to casting the water soluble film.
 65. A process as claimed inclaim 58 wherein active material is applied to the water soluble filmafter casting in a controlled dosing by spraying of premeasured materialto be embedded onto the cast film prior to drying.
 66. A process asclaimed in claim 58 further comprising the step of casting one or moreadditional water soluble films with or without embedded active materialonto the dried water soluble film at a secondary casting head andsmoothing and drying each additional film to form a multilayered watersoluble film.
 67. A process as claimed in claim 66 wherein theadditional water soluble film is dried at a temperature in the rangefrom 50° C. to 200° C., preferably 60° C. to 160° C., more preferably55° C. to 140° C.
 68. A process as claimed in claim 66 furthercomprising the step of passing the multilayered water soluble filmthrough a hot/chill device and optionally splitting the multilayeredwater soluble film prior to collection, for example in sheet or rollform.
 69. A process as claimed in claim 66 wherein multilayered watersoluble film comprises layers selected from one or more of cured film,uncured film, hot water soluble film, cold water soluble film, embeddedactive material film and liner.
 70. A process as claimed in claim 58further comprising the step of entrapping moistened active materialbetween two water soluble films.
 71. A process as claimed in claim 70wherein the entrapped active material is provided in selective areas ofthe water soluble film in desired shapes, for example with the use ofdimpled or other embossed or patterned designs.
 72. A water soluble filmsystem for delivering active ingredients in a controlled manner byembedding at least one active material in a single or multilayer watersoluble film for releasing the active material at precisely regulateddosages.